Kawasaki ER-6N - Owner's manual

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Quick Reference Guide

GENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

This Quick Reference Guide will

assist you in finding the information

you’re looking for.

A Table of Contents is included after

the Foreword.

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Whenever you see the symbols

shown below, heed their instructions!

Always follow safe operating and main-

tenance practices.

DANGER

DANGER indicates a hazardous

situation which, if not avoided,

will result in death or serious in-

jury.

WARNING

WARNING indicates a hazardous

situation which, if not avoided,

could result in death or serious

injury.

CAUTION

CAUTION indicates a hazardous

situation which, if not avoided,

could result in minor or moder-

ate injury.

NOTICE

NOTICE is used to address prac-

tices not related to personal in-

jury.

NOTE



This note symbol indicates points of

particular interest for more efficien t

and convenient operation.

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FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo-

torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,

and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will be

thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-

tures, capabilities, and limitations. This manual offers many safe riding tips, but its

purpose is not to provide instruction in all the techniques and skills required to ride

a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-

cle enroll in a motorcycle rider training program to attain awareness of the mental

and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and

maintenance described in this manual. For those who would like more detailed in-

formation on their Kawasaki Motorcycle, a Service Manual is available for purchase

from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-

tailed disassembly and maintenance information. Those who plan to do their own

work should, of course, be competent mechanics and possess the special tools

described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can

refer to it whenever you need information.

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This manual should be considered a permanent part of the motorcycle and should

remain with the motorcycle when it is sold.

prior written permission.

This publication includes the latest information available at the time of printing.

However, there may be minor differences between the actual product and illustra-

tions and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Consumer Products & Machinery Company

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TABLE OF CONTENTS

SPECIFICATIONS............................... 8

SERIAL NUMBER LOCATIONS......... 12

LOCATION OF PARTS ....................... 13

LOADING AND ACCESSORIES

INFORMATION ................................ 16

GENERAL INFORMATION................. 19

Meter Instruments ............................ 19

Speedometer: ............................... 20

Digital Meter: ................................ 20

Warning/Indicator Light:................ 28

Key................................................... 29

Ignition Switch/Steering Lock ........... 30

Right Handlebar Switches................ 32

Engine Stop Switch: ..................... 32

Starter Button: .............................. 33

Left Handlebar Switches .................. 33

Dimmer Switch: ............................ 33

Turn Signal Switch:....................... 34

Horn Button: ................................. 34

Hazard Switch: ............................. 34

Brake/Clutch Lever Adjusters........... 35

Fuel Tank Cap.................................. 36

Fuel Tank ......................................... 37

Fuel Requirement: ........................ 38

Stand................................................ 42

Seat.................................................. 43

Helmet Holding Cable ...................... 45

Tool Kit/U-Shaped Lock

Compartment................................ 46

Rear View Mirror .............................. 47

Tying Hooks ..................................... 48

BREAK-IN ........................................... 49

HOW TO RIDE THE MOTORCYCLE .51

Starting the Engine .......................... 51

Jump Starting ................................... 53

Moving Off........................................ 56

Shifting Gears .................................. 57

Braking............................................. 59

Stopping the Engine......................... 60

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Stopping the Motorcycle in an

Emergency ................................... 61

Parking............................................. 62

Catalytic Converter........................... 64

SAFE OPERATION............................. 66

Safe Riding Technique ..................... 66

Daily Safety Checks......................... 69

Additional Considerations for High

Speed Operation .......................... 72

MAINTENANCE AND ADJUSTMENT 74

Periodic Maintenance Chart............. 79

Engine Oil ........................................ 90

Cooling System ................................ 96

Spark Plugs...................................... 102

Evaporative Emission Control

System (California model only)..... 103

Kawasaki Clean Air System ............. 104

Valve Clearance ............................... 105

Air Cleaner ....................................... 106

Throttle Control System ................... 107

Engine Vacuum Synchronization ..... 110

Idle Speed ........................................ 110

Clutch............................................... 112

Drive Chain ...................................... 114

Brakes.............................................. 123

Brake Light Switches........................ 127

Front Fork......................................... 129

Rear Shock Absorbers ..................... 130

Wheels ............................................. 132

Battery.............................................. 138

Headlight Beam................................ 143

Fuses ............................................... 145

General Lubrication.......................... 147

Cleaning Your Motorcycle ................ 148

Bolt and Nut Tightening.................... 153

STORAGE........................................... 155

TROUBLESHOOTING GUIDE............ 157

OWNER SATISFACTION.................... 158

REPORTING SAFETY DEFECTS ...... 160

ENVIRONMENTAL PROTECTION..... 161

LOCATION OF LABELS..................... 162

MAINTENANCE RECORD ................. 173

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8 SPECIFICATIONS

SPECIFICATIONS

DIMENSIONS

Overall Length 2 100 mm (82.68 in.)

Overall Width 760 mm (29.92 in.)

Overall Height 1 100 mm (43.31 in.)

Wheelbase

1 405 mm (55.31 in.)

Road Clearance

140 mm (5.51 in.)

Curb Mass

200 kg (441 lb)

ENGINE

Type

DOHC, 4-valve, 2-cylinder, 4-stroke, liquid-cooled

Displacement

649 cm

3

(39.6 cu in.)

Bore × Stroke 83 × 60 mm (3.27 × 2.36 in.)

Compression Ratio

11.3 : 1

Starting System

Electric starter

Cylinder Numbering Method Left to right, 1-2

Firing Order

1-2

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SPECIFICATIONS 9

Carburetion System FI (Fuel Injection)

Ignition System Battery and coil (transistorized ignition)

Ignition Timing

10° BTDC @1 300 r/min (rpm) a

(Electronically advanced) 34° BTDC @5 000 r/min (rpm)

Spark Plugs NGK CR9EIA-9

Lubrication System Forced lubrication (semi-dry sump)

Engine Oil

Type :

API SG, SH, SJ, SL or SM with JASO MA, MA1

or MA2

SAE 10W-40

Capacity: 2.4 L (2.5 US qt)

Coolant Capacity 1.2 L (1.3 US qt)

TRANSMISSION

Transmission Type

6-speed, return shift

Clutch Type

Wet, multi disc

Driving System Chain drive

Primary Reduction Ratio

2.095 (88/42)

Final Reduction Ratio

3.067 (46/15)

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10 SPECIFICATIONS

Overall Drive Ratio 5.473 (Top gear)

Gear Ratio

1st

2.438 (39/16)

2nd

1.714 (36/21)

3rd

1.333 (32/24)

4th

1.111 (30/27)

5th

0.966 (28/29)

6th

0.852 (23/27)

FRAME

Castor 24.5°

Trail

102 mm (4.0 in.)

Tire Size:

Front

120/70 ZR 17 M/C (58 W)

Rear

160/60 ZR 17 M/C (69 W)

Rim Size:

Front

J17M/C × MT3.50

Rear

J17M/C × MT4.50

Fuel Tank Capacity 15.5 L (4.1 US gal)

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SPECIFICATIONS 11

ELECTRICAL EQUIPMENT

Battery 12 V 10 Ah

Headlight

12V55W/55W(Hi/Lo)

Tail/Brake Light

LED

Even if one of LED (Light Emitting Diode) tail/brake lights does not go on, consult

with an authorized Kawasaki dealer.

Specifications subject to change without notice.

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12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. They

are the only means of identifying your particular machine from others of the same

model type. These serial numbers may be needed by your dealer when ordering

parts. In the event of theft, the investigating authorities will require both numbers

as well as the model type and any peculiar features of your machine that can help

them identify it.

Frame No.

A. Frame Number

Engine No.

A. Engine Number

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LOCATION OF PARTS 13

LOCATION OF PARTS

1. Clutch Lever

2. Left Handlebar Switches

3. Meter Instruments

4. Brake Fluid Reservoir (Front)

5. Right Handlebar Switches

6. Front Brake Lever

7. Throttle Grip

8. Ignition Switch/Steering Lock

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14 LOCATION OF PARTS

9. Headlight

10. Turn Signal Light

11. Spark Plugs

12. Air Cleaner

13. Main Fuse

14. Battery

15. Seat

16. Tool Kit/Storage

Compartments

17. Helmet Holding Cable

18. Tying Hooks

19. Seat Lock

20. Front Fork

21. Brake Disc

22. Brake Caliper

23. Side Stand

24. Shift Pedal

25. Drive Chain

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LOCATION OF PARTS 15

26. License Plate Light

27. Tail/Brake Light

28. Brake Fluid Reservoir

(Rear)

29. Rear Shock Absorber

30. Spring Preload

Adjuster

31. Fuel Tank

32. Fuel Tank Cap

33. Coolant Reserve Tank

34. Muffler

35. Rear Brake Light

Switch

36. Rear Brake Pedal

37. Oil Level Gauge

38. Idle Adjusting Screw

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16 LOADING AND ACCESSORIES INFORMATION

LOADING AND ACCESSORIES INFORMATION

WARNING

Incorrect loading, improper in-

stallation or use of accessories,

or modification of your motorcy-

cle may result in an unsafe rid-

ing condition. Before you ride

the motorcycle, make sure that

the motorcycle is not overloaded

and that you have followed these

instructions.

With the exception of genuine

Kawasaki Parts and Accessories,

Kawasaki has no control over the

design or application of accessories.

In some cases, improper installation

or use of accessories, or motorcycle

modification, will void the motorcycle

warranty. In selecting and using acces-

sories, and in loading the motorcycle,

you are personally responsible for your

own safety and the safety of other per-

sons involved.

NOTE



Kawasaki Parts and Accessories

have been specially designed for

use on K awasaki motorcycles. We

strongly recommend that all parts

and accessories you add to y our

motorcycle be genuine Kawasaki

components.

Because a motorcycle is sensitive to

changes in weight and aerodynamic

forces, you must take extreme care in

carrying cargo, passengers and/or in

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LOADING AND ACCESSORIES INFORMATION 17

fitting additional accessories. The fol-

lowing general guidelines have been

prepared to assist you in making your

determinations.

1. Any passenger should be thor-

oughly familiar with motorcycle op-

eration. The passenger can affect

control of the motorcycle by im-

proper positioning during cornering

and sudden movements. It is impor-

tant that the passenger sit still while

the motorcycle is in motion and not

interfere with the operation of the

motorcycle. Do not carry animals

on your motorcycle.

2. You should instruct any passenger

before riding to keep his feet on the

passenger footpegs and hold on to

the operator or grab rail. Do not

carry a passenger unless he or she

is tall enough to reach the footpegs

and footpegs are provided.

3. All baggage should be carried as

low as possible to reduce the effect

on the motorcycle center of gravity.

Baggage weight should also be dis-

tributed equally on both sides of the

motorcycle. Avoid carrying baggage

that extends beyond the rear of the

motorcycle.

4. Baggage should be securely at-

tached. Make sure that the baggage

will not move around while you are

riding. Recheck baggage security

as often as possible (not while the

motorcycle is in motion) and adjust

as necessary.

5. Do not carry heavy or bulky items on

a luggage rack. They are designed

for light items, and overloading can

affect handling due to changes in

weight distribution and aerodynamic

forces.

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18 LOADING AND ACCESSORIES INFORMATION

6. Do not install accessories or carry

baggage that impairs the perfor-

mance of the motorcycle. Make

sure that you have not adversely

affected any lighting components,

road clearance, banking capability

(i.e., lean angle), control operation,

wheel travel, front fork movement,

or any other aspect of the motorcy-

cle’s operation.

7. Weight attached to the handlebar or

front fork will increase the mass of

the steering assembly and can re-

sult in an unsafe riding condition.

8. Fairings, windshields, backrests,

and other large items have the ca-

pability of adversely affecting stabil-

ity and handling of the motorcycle,

not only because of their weight, but

also due to the aerodynamic forces

acting on these surfaces while the

motorcycle is in operation. Poorly

designed or installed items can re-

sult in an unsafe riding condition.

9. This motorcycle is not intended to

be equipped with a sidecar or to be

used to tow any trailer or other ve-

hicle. Kawasaki does not manu-

facture sidecars or trailers for mo-

torcycles and cannot predict the ef-

fects of such accessories on han-

dling or stability, but can only warn

that the effects can be adverse and

that Kawasaki cannot assume re-

sponsibility for the results of such

unintended use of the motorcycle.

Furthermore, any adverse effects on

motorcycle components caused by

the use of such accessories will not

be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage,

and accessories must not exceed 180 kg

(397 lb).

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Kawasaki ER-6N - Owner's manual

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